Parts sorting with removable binsMade using empty yoghurt cups
This article also available in Spanish
So I had the idea of using these small square-ish yoghurt cups for parts trays. All I need is a rack to hold them.
I resawed these on the table saw, using a thin kerf 7¼" skillsaw blade. I had to cut in from both sides.
2x4 lumber often has internal tension from how it was dried, so it sometimes pinches in on the blade. Cutting just half the depth from each side makes it easier to control.
Next, I set up my dado stack to cut an 8 mm wide slot. I hadn't used my dado set in years. Mostly, I just make multiple cuts, but I needed to cut quite a few notches consistently so, in this case, setting up the dado stack was worth it.
To make for five equal sized spaces, I used this shop trick. Basically, subtracting the width of the final divider, that leaves the remaining space for five cups and five dividers. So after subtracting 8 mm from the total width, I divide what's left by 5. Measuring from the right side, that tells me where all the right edges of the dividers need to be.
I would have used a small clamp, but there was no place to put one.
I initially thought of starting with the outside, but the outside interlocks much less, and it's also much easier to force the outside parts on after the inside is assembled. I didn't want to have to push too many joints together at once.
Even so, I did get stuck on one joint, and had to grab a mallet and another piece of wood to drive it all the way in.
I had marked the pieces to make sure I wouldn't flip any, but still ended up flipping one. With fraction of a millimeter errors in where I cut the notches, this meant the pieces of wood had to bend a bit to fit, and so I needed some clamps to force the outside joints all fully closed.
Now I just need to eat some more yoghurt to get enough empty cups!
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